Did you pull the factory studs and replace with bolts? The hex on the studs won't allow the up pipe to fully tighten down, if I'm remembering correctly.
I've had four 5.4 3v engines. Highest mileage one had 180k on it when I sold it. AFAIK original timing components on every engine and have never had a problem. Granted that's not crazy high mileage but to say they're junk at 100k is a bit of a stretch lol.
Sold a guy some auger flighting and an outer pipe the other day. He's going to build his own muffler for a Kenworth with it. Curious to hear how it sounds.
I'm no expert but looks to me like the door isn't shutting tightly enough. Should be flush with the panel behind it instead of protruding out a bit. Could just be the angle of the picture tho...
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